Surface cleaning apparatus

ABSTRACT

A surface cleaning apparatus such as a vacuum cleaner ( 10 ) includes a suction source ( 18 ), a recovery container, and a base assembly ( 34 ) with at least one agitator ( 26 ) within an agitator chamber ( 74 ). The recovery container ( 20 ) can be coupled to a separator assembly ( 140 ) configured to remove dirt and debris from working fluid through the surface cleaning apparatus ( 10 ). In addition, a user interface ( 84 ) can be provided for selective operation of components of the surface cleaning apparatus ( 10 ).

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication No. 62/690,371, filed Jun. 27, 2018 which is incorporatedherein by reference in its entirety.

BACKGROUND

Surface cleaning apparatuses such as vacuum cleaners are well-knowndevices for removing dirt and debris from a variety of surfaces such ascarpets, hard floors, or other fabric surfaces such as upholstery. Suchsurface cleaning apparatuses typically include a recovery systemincluding a recovery container, a nozzle adjacent the surface to becleaned and in fluid communication with the recovery container through aconduit, and a source of suction in fluid communication with the conduitto draw debris-laden air from the surface to be cleaned and through thenozzle and the conduit to the recovery container.

BRIEF DESCRIPTION

In one aspect, the disclosure relates to a vacuum cleaner, including abase assembly including a suction nozzle and adapted for movement alonga surface to be cleaned, a hand-held portion having a hand grip and asuction source in fluid communication with the suction nozzle andconfigured for generating a working airstream, a working air path fromthe suction nozzle to an air outlet in the hand-held portion andincluding the suction source, and a headlight array located along aforward oriented portion of the base assembly, providing a beam that issubstantially parallel to the surface to be cleaned and spaced above thesurface to be cleaned at not more than 30 mm.

In yet another aspect, the disclosure relates to a vacuum cleaner,including a base assembly including a suction nozzle and adapted formovement along a surface to be cleaned, a hand-held portion having ahand grip, a recovery container with a collector axis defined through acenter thereof, and a suction source in fluid communication with thesuction nozzle and the recovery container and configured for generatinga working airstream, and a wand operably coupled between the baseassembly and the hand-held portion and defining at least a portion of aworking air path extending from the suction nozzle to an air outlet inthe hand-held portion and including the suction source and wherein awand axis is defined through a center of the wand and wherein the wandaxis and the collector axis are parallel.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a schematic view of a surface cleaning apparatus according tovarious aspects described herein.

FIG. 2 is a perspective view of the surface cleaning apparatus of FIG. 1in the form of a hand-held vacuum cleaner including a base assembly andan upright assembly according to various aspects described herein.

FIG. 3 is a partially-exploded view of the vacuum cleaner of FIG. 2.

FIG. 4 is a side sectional view of the vacuum cleaner of FIG. 2 alongline IV-IV.

FIG. 5 is a perspective view of a hand grip of FIG. 2 including a userinterface according to various aspects described herein.

FIG. 6 is a partially-exploded view of the hand grip of FIG. 5 with auser interface in a first configuration.

FIG. 7 is a sectional view of the hand grip and user interface of FIG.6.

FIG. 8 is a sectional view of a hand-held vacuum cleaner portion of theupright assembly of FIG. 2 along line IV-IV.

FIG. 9 is a sectional view of a dirt separation and collection module inthe hand-held vacuum cleaner portion of FIG. 8 according to variousaspects described herein.

FIGS. 10A-10B illustrates an emptying process for the dirt separationand collection module of FIG. 9.

FIG. 11 is a partially-exploded view of a wand of the vacuum cleaner ofFIG. 2 according to various aspects described herein.

FIG. 12 is a sectional view of the wand of FIG. 11 along line XII-XII.

FIG. 13 is a partially-exploded view of another wand that can beutilized in the vacuum cleaner of FIG. 2 according to various aspectsdescribed herein.

FIG. 14 is a sectional view of the wand of FIG. 13 along line XIV-XIV.

FIG. 15 is a partially-exploded view of the base assembly of FIG. 2according to various aspects described herein.

FIG. 16 is a perspective view of a brushroll that can be utilized in thebase assembly of FIG. 2 according to various aspects described herein.

FIG. 17 is a sectional view of the base assembly of FIG. 2.

FIG. 18 is a partially-exploded view of the base assembly of FIG. 2illustrating an alternate brushroll that can be utilized in the baseassembly.

FIG. 19 is a sectional view of the base assembly of FIG. 2.

DETAILED DESCRIPTION

The disclosure relates to a surface cleaning apparatus such as ahand-held surface cleaner that cleans debris from the surface. Suchhand-held cleaners can be in the form of a stick vacuum or wand vacuum.The surface cleaning apparatus also includes a hand grip with a userinterface for selective operation of components of the surface cleaningapparatus. A base assembly can include an agitator chamber and anaperture. At least one agitator can be slidably received in the agitatorchamber through the aperture.

FIG. 1 is a schematic view of various functional systems of a surfacecleaning apparatus in the form of an exemplary vacuum cleaner 10. Thefunctional systems of the exemplary vacuum cleaner 10 can be arrangedinto any desired configuration including as a portable cleaner adaptedto be hand carried by a user for cleaning relatively small areas. Thevacuum cleaner 10 can be adapted to include a hose or other conduit,which can form a portion of the working air conduit between a nozzle andthe suction source.

The vacuum cleaner 10 can include a recovery system 14 for removingdebris from the surface to be cleaned and storing the debris. Therecovery system 14 can include a suction inlet or suction nozzle 16, asuction source 18 in fluid communication with the suction nozzle 16 forgenerating a working air stream, and a recovery container 20 forseparating and collecting debris from the working airstream for laterdisposal.

The suction nozzle 16 can be provided on a base or cleaning head adaptedto move over the surface to be cleaned. An agitator 26 can be providedadjacent to the suction nozzle 16 for agitating the surface to becleaned so that the debris is more easily ingested into the suctionnozzle 16. Some examples of agitators 26 include, but are not limitedto, a horizontally-rotating brushroll, dual horizontally-rotatingbrushrolls, one or more vertically-rotating brushrolls, or a stationarybrush.

The suction source 18 can be any suitable suction source and is providedin fluid communication with the recovery container 20. The suctionsource 18 can be electrically coupled to a power source 22, such as abattery or by a power cord plugged into a household electrical outlet. Asuction power switch 24 between the suction source 18 and the powersource 22 can be selectively closed by the user, thereby activating thesuction source 18.

A separator 21 can be formed in a portion of the recovery container 20for separating entrained debris from the working airstream.

The vacuum cleaner 10 shown in FIG. 1 can be used to effectively removedebris from the surface to be cleaned in accordance with the followingmethod. The sequence of steps discussed is for illustrative purposesonly and is not meant to limit the method in any way as it is understoodthat the steps may proceed in a different logical order, additional orintervening steps may be included, or described steps may be dividedinto multiple steps.

In operation, the vacuum cleaner 10 is prepared for use by coupling thevacuum cleaner 10 to the power source 22. During operation of therecovery system 14, the vacuum cleaner 10 draws in debris-laden workingair through the suction nozzle 16 and into the downstream recoverycontainer 20 where the fluid debris is substantially separated from theworking air. The airstream then passes through the suction source 18prior to being exhausted from the vacuum cleaner 10. The recoverycontainer 20 can be periodically emptied of collected fluid and debris.

FIG. 2 is a perspective view illustrating a vacuum cleaner 10 accordingto various aspects described herein. For purposes of description relatedto the figures, the terms “upper,” “lower,” “right,” “left,” “rear,”“front,” “vertical,” “horizontal,” “inner,” “outer,” and derivativesthereof shall be described from the perspective of a user behind thevacuum cleaner 10, which defines the rear of the vacuum cleaner 10.However, it is to be understood that the disclosure may assume variousalternative orientations, except where expressly specified to thecontrary.

In the illustrated example, the vacuum cleaner 10 can include a housing30 with an upright assembly 32 and a base assembly 34. The uprightassembly 32 can be pivotally connected to the base assembly 34 fordirecting the base assembly 34 across the surface to be cleaned. It iscontemplated that the vacuum cleaner 10 can include any or all of thevarious systems and components described in FIG. 1, including a recoverysystem 14 for separating and storing dirt or debris from the surface tobe cleaned. The various systems and components schematically describedfor FIG. 1 can be supported by either or both the base assembly 34 andthe upright assembly 32 of the vacuum cleaner 10.

FIG. 3 illustrates a partially-exploded view of the vacuum cleaner 10 ofFIG. 2. The upright assembly 32 includes a hand-held portion 36supporting components of the recovery system 14, including, but notlimited to, the suction source 18 and the recovery container 20. By wayof non-limiting example, the suction source 18 can includes a motor/fanassembly 124 (FIG. 8).

The hand-held portion 36 can be coupled to a wand 40 having at least onewand connector 42. In the illustrated example, both a first end 44 ofthe wand 40 and a second end 46 of the wand 40 include a wand connector42. The wand connector 42 at the second end 46 of the wand 40 can becoupled to the base assembly 34 via a wand receiver 48. The wandconnector 42 at the first end 44 of the wand 40 can couple to a secondwand receiver 50 within the hand-held portion 36. It is contemplatedthat the wand connectors 42 can be the same type of connector or canvary. Any suitable type of connector mechanism can be utilized, such asa quick connect mechanism or a tubing coupler in non-limiting examples.

A pivotal connection between the upright assembly 32 and the baseassembly 34 can be provided by at least one pivoting mechanism. In theillustrated example, the pivoting mechanism can include a multi-axisswivel joint assembly 52 configured to pivot the upright assembly 32from front-to-back and side-to-side with respect to the base assembly34. A lower portion 54 of the swivel joint assembly 52 is locatedbetween the wand 40 and the base assembly 34. The lower portion 54 ofthe swivel joint assembly 52 provides for pivotal forward and backwardrotation between the wand 40 and the base assembly 34. An upper portion56 of the swivel joint assembly 52 is also located between the wand 40and the base assembly 34 and provides for lateral or side-to-siderotation between the wand 40 and base assembly 34. More specifically,the lower portion 54 of the swivel joint assembly 52 is coupled betweenthe base assembly 34 and the upper portion 56 of the swivel jointassembly 52. The upper portion 56 of the swivel joint assembly 52 iscoupled to the wand receiver 48 at the second end 46 of the wand 40.Wheels 58 can be coupled to the lower portion 54 of the swivel jointassembly 52 or directly to the base assembly 34, and are adapted to movethe base assembly 34 across the surface to be cleaned.

The hand-held portion 36 can also include the recovery container 20,illustrated herein as a dirt separation and collection module 60 fluidlycoupled to the suction source 18 via an air outlet port 62. The dirtseparation and collection module 60 can be removable from the hand-heldportion 36 by a release latch 64 as shown so that it can be emptied ofdebris.

An upper end of the hand-held portion 36 can further include a hand grip66 for maneuvering the vacuum cleaner 10 over a surface to be cleanedand for using the vacuum cleaner 10 in hand-held mode. At least onecontrol mechanism 68 is provided on the hand grip 66 and coupled to thepower source 22 (FIG. 1) for selective operation of components of thevacuum cleaner 10. In the contemplated example, the at least one controlmechanism 68 is an electronic control that can form the suction powerswitch 24.

The agitator 26 of the illustrated embodiment includes a brushroll 70(FIG. 4) configured to rotate about a horizontal axis and operativelycoupled to a drive shaft of a drive motor via a transmission, which caninclude one or more belts, gears, shafts, pulleys, or combinationsthereof. An example of which will be explained in more detail below. Anagitator housing 72 is provided around the suction nozzle 16 and definesan agitator chamber 74 (FIG. 4) for the brushroll 70 (FIG. 4).

Referring now to FIG. 4, a recovery airflow conduit 75 can be formedbetween the agitator housing 72 and the dirt separation and collectionmodule 60. For example, a hose conduit 76 in the base assembly 34 can befluidly coupled to a wand central conduit 78 within the wand 40. Thehose conduit 76 can be flexible to facilitate pivoting movement of theswivel joint assembly 52 about multiple axes. The wand central conduit78 is fluidly connected to a dirt inlet 80 on the dirt separation andcollection module 60 via the air outlet port 62.

In the illustrated example, the power source 22 is in the form of abattery pack 82 containing one or more batteries, such as lithium-ion(Li-Ion) batteries. Optionally, the vacuum cleaner 10 can include apower cord (not shown) to connect to a wall outlet. In still anotherexample, the battery pack 82 can include a rechargeable battery pack,such as by connecting to an external source of power to rechargebatteries contained therein.

During operation of the vacuum cleaner 10, the power source 22 cansupply power for the suction source 18, such as by way of non-limitingexample a motor/fan assembly 124 (FIG. 8) to provide suction through therecovery airflow conduit 75. Debris-laden working air within theagitator housing 72 can be directed through the flexible hose conduit 76and wand central conduit 78 before flowing into the dirt separation andcollection module 60 by way of the dirt inlet 80 as shown. In addition,the swivel joint assembly 52 can provide for forward/backward andside-to-side pivoting motion of the upright assembly 32 with respect tothe base assembly 34 when moving the base assembly 34 across the surfaceto be cleaned. Additional details of the motor/fan assembly 124 (FIG. 8)are described in U.S. Pat. No. 10,064,530, issued Sep. 4, 2018, which isincorporated herein by reference in its entirety.

FIG. 5 illustrates an exemplary hand grip 66 that can be utilized in thevacuum cleaner 10. The hand grip 66 can include a user interface 84 withat least one status indicator for a component of the vacuum cleaner 10.The status indicator is illustrated in the form of a suction levelindicator 86 and a battery level indicator 88. While not shown, otherstatus indicators can be provided on the user interface 84. Innon-limiting examples, an LED or text display (not shown) can alsoindicate that a filter is clogged, that the recovery container 20 needsemptying, or that a brushroll 70 needs cleaning or inspecting.

The suction level indicator 86 is illustrated as being positioned atlateral edges of the user interface 84 and can illuminate to show acurrent level of suction power. More specifically, threeprogressively-illuminated LEDs 90 can be positioned at each lateral edgeto indicate a level of suction between “high,” “medium,” and “low”suction powers for the suction level indicator 86. For example, repeatedpressing of a suction mode selector button 92 can cycle through the“high,” “medium,” and “low” suction power levels, and each LED 90 of thesuction level indicator 86 can illuminate in sequence accordingly. Inthe illustrated example, the “medium” suction power level is shownwherein two of the three LEDs 90 are illuminated on the suction levelindicator 86 of the user interface 84. It will be understood that, inthe illustrated example, the suction mode selector button 92 isconfigured to operate the suction source 18 (FIG. 2) with low, medium,and high suction power, which in turn operates the suction source 18including the motor/fan assembly 124 (FIG. 8) at predetermined low,medium and high rotational speeds. Further still, a power button 94 canbe positioned adjacent the suction mode selector button 92 or elsewhereon the user interface 84 to selectively power the suction source 18.

The battery level indicator 88 is in the form of a series of lights,such as light-emitting diodes (LEDs) 96 that progressively illuminate toshow a level of charge of the battery pack 82. In an alternate example,the battery level indicator 88 can be in the form of a pre-drawn icondisplayed on a screen to indicate a level of charge of the battery pack82.

FIG. 6 illustrates an exploded view of the hand grip 66 of FIG. 5, whichmore clearly illustrates that the LEDs 90 and 96 can be provided withina substructure of the hand grip 66. An upper grip 100 with an aperture102 configured to receive and surround the power button 94 and suctionmode selector button 92. A lower grip 104 coupled to the upper grip 100can include a reflective concave portion 106, such as a white-colored orreflective or mirrored surface. The lower grip 104 can also include aplurality of divider walls 108 to isolate light emitted by the LEDs 90and 96. The LEDs 90 (FIGS. 7) and 96 (FIG. 5 for the suction levelindicator 86 and the battery level indicator 88, respectively, can bepositioned on a printed circuit board (PCB) 110. In addition, anisolator 112 can be coupled to the PCB 110 and include a first seat 116a for the power button 94 and a second seat 116 b for the suction modeselector button 92. The isolator 112 can include openings 118 a, 118 balong each lateral edge to permit light for the suction level indicator86 to be emitted. The isolator 112 can further include additionalopenings 120 through which the LEDs 96 can shine for the battery levelindicator 88.

FIG. 7 illustrates the assembled hand grip 66. As assembled within thehand grip 66, the PCB 110 defines a lower surface 114 a and an uppersurface 114 b. The LEDs 90 for the suction level indicator 86 arepositioned on the lower surface 114 a of the PCB 110 and emit lightdownward, toward the lower grip 104 as illustrated by first arrows 123.The reflective concave portion 106 of the lower grip 104 reflects theemitted light upward, toward the upper grip 100. Overmolded portions 122of the lower grip 104 can block or redirect emitted light from the LEDs90 to shine upwardly toward the isolator 112. The openings 118 a, 118 balong each lateral edge of the isolator 112 permit the emitted light toshine through at the edges of the upper grip 100, as indicated via arrow125, thereby forming the suction level indicator 86 at each lateral edgeof the hand grip 66. It is further contemplated that the upper grip 100can include molded or shaped portions to further direct or diffuse theemitted light, such as a translucent portion forming a viewing windowfor each LCD in the suction level indicator 86.

Turning to FIG. 8, the assembled hand-held portion 36 of the uprightassembly 32 is shown including a portion of the wand 40, the batterypack 82, the hand grip 66, the motor/fan assembly 124, and the dirtseparation and collection module 60.

As illustrated, a wand axis 126 can be defined through the center of thewand 40 (FIG. 4) and wand connector 42. In FIG. 8 the wand 40 is heldupright, and thus the wand axis 126 is vertical. In this example,references to “a vertical axis” will be understood to also refer to thewand axis 126. It will be understood, that during use the wand 40 may beoriented in any suitable manner including angled with respect to thevertical axis.

A collector axis 128 can be defined through the center of the dirtseparation and collection module 60, and a motor axis 130 can be definedthrough the center of the motor/fan assembly 124. It is contemplatedthat the wand axis 126, the collector axis 128, and the motor axis 130can all be parallel to one another as shown. Put another way, when thewand 40 is held upright such that the wand axis 126 is vertical, thecollector axis 128 and the motor axis 130 are also vertical.

A grip axis 132 can be defined through the center of the hand grip 66 asshown. The grip axis 132 forms a grip angle 134 with respect to avertical direction, such as 60 degrees in a non-limiting example.Further, a battery axis 136 can be defined through the center of thebattery pack 82 and intersect the grip axis 132. The battery axis 136can also define a battery angle 138 with respect to a verticaldirection, such as 30 degrees in a non-limiting example. Optionally, thegrip axis 132 can be orthogonal to the battery axis 136.

FIG. 9 illustrates additional details of the dirt separation andcollection module 60. The dirt separation and collection module 60 caninclude a dirt cup in the form of recovery container 20 with an inletport in the form of the dirt inlet 80, and a separator assembly 140coupled to the recovery container 20. Working air can enter through thedirt inlet 80 and swirls around a first stage separator assembly chamber144 for centrifugally separating debris from the working air flow. Theseparator assembly 140 includes a first stage separator 142, such as agrill, that, in combination with the swirling working air, removesrelatively large debris out of the working air which collects at a lowerportion of the recovery container 20 defining a first stage collectionarea 146.

The working air moves through an inlet to a second stage separator 148in the separator assembly 140, such as a grill or a mesh configured tofilter smaller debris, and enters a second stage separation chamber 150,which is shown as a cyclonic separator herein. Smaller debris removedfrom the working air collects in a second stage collector 152 near thebottom of the recovery container 20. The first stage collector 146 cansurround the second stage collector 152 as shown.

An exhaust outlet 154 and filter housing 158 are fluidly coupled to anupper portion of the second stage separation chamber 150. Withadditional reference to FIG. 8, working air exits the second stageseparation chamber 150 through the exhaust outlet 154 and at least onefilter in the filter housing 158 and which is shown herein as apre-motor filter 156 of the motor/fan assembly 124. The filtered workingair flows into the motor/fan assembly 124 whereupon it can be exhaustedinto the surrounding atmosphere through an exhaust filter, i.e. apost-motor filter 155, and an air outlet of the working air pathwaythrough the vacuum cleaner 10, which is shown herein as formed by anexhaust grill 153.

The outer surface of the first stage separator 142 can accumulatedebris, such as hair, lint, or the like that may become stuck thereonand may not fall into the first stage collection area 146. FIG. 10Ashows the separator assembly 140 being removed and FIG. 10B shows theseparator assembly 140 fully removed from the recovery container 20 toempty collected dirt and debris from the first and second stagecollection areas 146 and 152.

The separator assembly 140 can further include a ring 161 slidablycoupled to the recovery container 20. The ring 161 can be coupled to awiper 160, such as an annular wiper, configured to contact the firststage separator 142. The separator assembly 140 can be lifted upwardswith respect to the ring 161 and recovery container 20. During thislifting, the ring 161 temporarily remains coupled to the recoverycontainer 20, either by friction fit or a mechanical coupling such asbayonet hook, for example, and the wiper 160 slides or scrapes along thefirst stage separator 142 to remove accumulated debris from the outersurface of the first stage separator 142 or grill, which falls down tothe first stage collection area 146.

When the separator assembly 140 has been raised to a predeterminedlevel, it can lift away from the recovery container 20 along with thering 161 and wiper 160. The recovery container 20 can then be invertedto remove dirt and debris from the first and second stage collectionareas 146 and 152. After emptying, the separator assembly 140 can berepositioned within the recovery container 20 and the ring 161 can onceagain be coupled to the recovery container 20 for additional use of thevacuum cleaner 10.

FIG. 11 shows additional details of an exemplary wand assembly, whichcan include a wand body 162 enclosing the wand central conduit 78. Inone example, the wand body 162 can be formed from an extrusion ofaluminum, and is illustrated as having an exterior rounded triangulargeometric profile defining an outer periphery 168 (FIG. 12). Wandconnectors 42 can couple to the wand body 162 at each end 44 and 46. Afirst wand connector 42 can couple the wand body 162 to the baseassembly 34 and a second wand connector 42 can couple the wand body 162to the hand-held portion 36 (FIG. 3).

A decorative insert 166 can be coupled to at least a portion of the wandbody 162. In the illustrated example, the decorative insert 166 can bein the form of a flat plate and configured to couple to a recessedportion defining a face 164 of the triangular shaped wand body 162.Optionally, the decorative insert 166 can included rounded edges to formsmooth surface transitions between an outer surface of the decorativeinsert and a second face of the wand body. It is contemplated that thedecorative insert 166 can be formed of plastic, including transparent ortranslucent plastic. Optionally, the decorative insert 166 can includelogos or other markings or indicators for operations of the vacuumcleaner 10, or locating features so as to couple a correct end of thewand body 162 to one of the base assembly 34 or hand-held portion 36 ofthe upright assembly 32, for example.

FIG. 12 illustrates a sectional view of the wand 40. It is contemplatedthat the wand body 162 can include an outer wall defining the outerperiphery 168 with at least one inner partition 170 defining the wandcentral conduit 78. The outer wall defining the outer periphery 168 isfurther illustrated as including a hook 172 defining a correspondingrecess 174 on either side of the face 164. Protrusions 176 on eitherside of the decorative insert 166 can be received within the recesses174. It is contemplated that the protrusions 176, or the entiredecorative insert 166, can have material flexibility such that theprotrusions 176 can be “snap-fit” into the recesses 174 of the wand body162. In another non-limiting example, the protrusions 176 can be made ofa material having higher elasticity than that of a remainder of thedecorative insert 166, such as a plastic decorative insert having rubberhooked portions configured to snap-fit or snugly insert into therecesses 174 of the wand body 162.

FIG. 13 illustrates another embodiment of a wand assembly that can beutilized in the vacuum cleaner 10. In the illustrated example, the wandbody 162 a can have a generally V-shaped geometric profile with an openface 163 on one side, such as by forming a V-shaped extrusion ofaluminum. A tubular member 165 can be coupled within the wand body 162a. The tubular member 165 can have an inner surface defining the wandcentral conduit 78 a, and an outer surface shaped to form a smoothsurface transition between the tubular member 165 and the wand body 162a.

FIG. 14 illustrates a sectional view with the tubular member 165 aassembled within the wand body 162 a. The wand body 162 a can have anouter wall 168 a with at least one projection 176 a. The tubular member165 a can have a corresponding at least one recess 172 c formed byspaced walls 172 a and 172 b. The at least one recess 172 c isconfigured to surround the at least one projection 176 a to securely fixthe tubular member 165 a in place. In one example, the at least oneprojection 176 a can be formed from an elastic material to provide“snap-fit” coupling between the tubular member 165 a and wand body 162a. In another example, the wand body 162 a can have sufficientelasticity such that the tubular member 165 a can be press-fit into thewand body 162 a, and the at least one projection 176 a can “snap” intoplace within the corresponding at least one recess 172 c.

The tubular member 165 a can be formed from a transparent material suchas extruded thermoplastic or polycarbonate material. In such a case, theassembled wand would include a transparent face defined by the exposedface of the tubular member 165 a when assembled within the wand body 162a. In this configuration, a transparent tubular member would providevisibility within the wand central conduit 78 a, such that dirt anddebris moving through the conduit would be visible to a user duringoperation of the vacuum cleaner 10. Additionally, potential obstructionsor clogs within the tubular member could also be viewed in a facilemanner through the transparent tubular member. A transparent section 167has been illustrated in the tubular member 165 a by way of non-limitingexample.

FIG. 15 illustrates one embodiment of a base assembly 34. The baseassembly 34 can extend between a first side 180 and a second side 182and a cover 184 can at least partially define the agitator chamber 74therebetween. An aperture 186 is located in a portion of the second side182 and allows for insertion and removal of the brushroll 70. A frontbar 188 extends between the first side 180 and the second side 182 alonga lower portion of the base assembly. The front bar 188 is configured tobe located behind the cover 184 when the cover 184 is mounted. Aheadlight array 190 is illustrated as being located on the front bar 188and extending along the width of the base assembly between the firstside 180 and the second side 182. The headlight array 190 can be anysuitable illumination assembly including an LED headlight array. Eventhough the headlight array 190 is positioned under the cover 184 it canbe considered to be positioned along an outer portion of the baseassembly 34. In one example, the cover 184 can include a transparentportion such that when installed, the transparent portion covers andprotects the headlight array 190 and permits emitted light to shinethrough to the surface to be cleaned. In another example, the cover 184can leave the headlight array 190 uncovered so as not to block emittedlight from the headlight array 190.

A brushroll 70 can be positioned within the agitator chamber 74 bysliding a first end through the aperture 186 located at the second side182 of the base assembly 34. When fully inserted, a second end 70 b ofthe brushroll 70 can be flush with the aperture 186. In addition, thehose conduit 76 can fluidly couple the agitator chamber 74 to the wandcentral conduit 78 (FIG. 4).

The base assembly 34 can include a brush drive assembly 192 positionedopposite the aperture 186 and configured to drive rotational motion ofthe agitator 26 (e.g. brushroll 70) within the agitator chamber 74. Thebrush drive assembly 192 can have components including, but not limitedto, a brush motor 226, a belt 228 within a belt housing 229, and a brushdrive gear 220.

Additional details of the brushroll 70 are shown in FIG. 16. The firstend of the brushroll 70 can include an end plate 194 having projections196, such as teeth, configured to engage a portion of the brush driveassembly 192 (FIG. 15). The brushroll 70 further includes a centralshaft 222 coupled to brush bearings 224 (FIG. 17) at each end. In theillustrated example, the brushroll 70 includes a bristled brushroll 70with offset, swept tufts 202 extending along an outer surface of thebrushroll 70. The bristle tufts 202 can be positioned offset from acenter line 204 of a tufting platform 206, and the tufts 202 can also benon-orthogonal to the tufting platform 206. In this manner, the bristledbrushroll 70 can be configured to prevent hair from wrapping around thebrushroll 70 during operation. Additional details of a similar brushrollare described in U.S. Publication No. 2018-0125315, which isincorporated herein by reference in its entirety.

The assembled base assembly 34 is shown in FIG. 17, where theprojections 196 of the end plate are coupled with the brush drive gear220. In this manner the brush drive gear 220 is also coupled to theshaft 222 by way of a drive gear bearing 229. With additional referenceto FIG. 15, as the brush motor 226 drives rotation of the belt 228 andbrush drive gear 220, the brushroll 70 can be rotated at a variety ofspeeds depending on the selected suction mode (FIG. 5). A brush removalendcap 230 at the second end of the brushroll 70 provides for unlockingor removal of the brushroll 70 from the agitator chamber 74, such as forcleaning of the bristle tufts 202.

It is contemplated that a variety of agitators 26 and brushrolls 70 canbe utilized within the agitator chamber 74. FIG. 18 illustrates amicrofiber brushroll 210 that can be utilized. The microfiber brushroll210 is similar to the bristled brushroll 70; one difference is the outersurface includes a microfiber layer instead of bristles. Whereasbristles can be utilized to lift hair and debris from carpet fibers, themicrofiber layer can lift dirt and debris from hard surfaces such aswood or tile. Each of the brushrolls can include a brush removal endcap198 including fasteners 212. In the illustrated example, the fasteners212 include bayonet fasteners wherein a given brushroll is insertedthrough the aperture 186 and rotated, for example by 30 degrees, to lockthe brushroll into place within the agitator chamber 74 (FIG. 19) viacorresponding fastener receivers 214. It will be understood that otherbrushroll types not explicitly described can be utilized in the vacuumcleaner 10.

FIG. 19 illustrates the base assembly 34 sitting on a surface to becleaned, the surface to be cleaned defining a first plane 230. Asillustrated in cross-sectional view a center line of the headlight array190 can be defined as a second plane 232. The second plane 232 is spacedabove the first plane defined by the surface to be cleaned by a height234. It has been determined that providing the headlight array 190 closeto the first plane 230 and relatively low on the base assembly 34provides unexpected benefits. The height can be any suitable smallheight that provides such benefits including, by way of non-limitingexamples, spaced above the surface to be cleaned at not more than 30 mm,at less than 20 mm, and at 15.8 mm. Further still, by way ofnon-limiting example, the illuminance measurements as a delta fromambient values at 2 meters from the headlight array 190 can be 16 Luxand at 10 cm can be greater than 1000 Lux. In another example, theheadlight array 190 can be aligned with the lower front edge of thefront bar 188.

More specifically, during operation of the vacuum cleaner 10 when theheadlight array 190 provides illumination it has been determined thatthe placement of the headlight array 190 in this very low positionacross the front of the base assembly 34 illuminates the surface to becleaned very well, including that dust and/or debris are illuminatedexceptionally well. It has been determined that performance isnoticeably better as compared to when LEDs are mounted higher up andpointing downwardly at the surface to be cleaned. Because of the lowposition of the headlight array 190 and because the headlight array 190faces forward and projects illumination at substantially a horizontalprojection along the second plane 232 shadows are cast by debris on thesurface to be cleaned and these shadows are very obvious to a user ofthe vacuum cleaner 10. It will be understood that the beam provided bythe headlight array 190 can be projected with a zero-degree angle thatprovides a beam that is parallel to the surface to be cleaned as definedby the first plane 230.

To the extent not already described, the different features andstructures of the various embodiments of the present disclosure may beused in combination with each other as desired. Thus, the variousfeatures of the different embodiments may be mixed and matched asdesired to form new embodiments, whether or not the new embodiments areexpressly described.

For example, various characteristics, aspects, and advantages of thepresent invention may also be embodied in the following technicalsolutions defined by the following clauses and may include anycombination of the following concepts:

A vacuum cleaner, comprising:

a base assembly including a suction nozzle and adapted for movementalong a surface to be cleaned;

a hand-held portion having a handle grip and a suction source in fluidcommunication with the suction nozzle and configured for generating aworking airstream;

a working air path from the suction nozzle to an air outlet in thehand-held portion and including the suction source; and

a headlight array located along a forward oriented portion of the baseassembly, providing a beam that is substantially parallel to the surfaceto be cleaned and spaced above the surface to be cleaned at not morethan 30 mm.

2. The vacuum cleaner of clause 1 wherein the headlight array includes aplurality of LEDs spaced along a width of the base assembly.

3. The vacuum cleaner of clause 2 wherein the plurality of LEDs have acenterline that is less than 20 mm above a plane defined by the surfaceto be cleaned.

4. The vacuum cleaner of clause 2 wherein the plurality of LEDs providean illuminance measurement as a delta from ambient values of at least 16Lux at 2 meters and greater than 1000 Lux at 10 cm.

5. The vacuum cleaner of any permutation of the clauses 1-4 wherein thebeam is at a zero-degree beam angle.

6. The vacuum cleaner of any permutation of the clauses 1-5 wherein theworking air path is at least partially defined by a wand operablycoupled between the base assembly and the hand-held portion.

7. The vacuum cleaner of clause 6 wherein the wand comprises an outerperiphery having a triangular profile.

8. The vacuum cleaner of clause 7 wherein the wand includes a decorativeinsert operably coupled to a recess within a wand body and thedecorative insert and the wand body together form the outer periphery orwherein the wand includes a tubular insert operably coupled within arecess of a wand body and the tubular insert and the wand body togetherform the outer periphery.

9. The vacuum cleaner of clause 6, further comprising a swivel jointmoveably coupling a lower end of the wand to the base assembly.

10. The vacuum cleaner of clause 6 wherein the hand-held portion furthercomprises a debris removal assembly including a recovery containerprovided in fluid communication with the suction source.

11. The vacuum cleaner of clause 10 wherein the suction source includesa motor/fan assembly operably coupled to the debris removal assembly toform a single, hand-carriable unit.

12. The vacuum cleaner of clause 11 wherein the hand grip extends awayfrom at least one of the motor/fan assembly or the recovery container todefine a handle opening and where the handle grip is adapted to begripped by a user.

13. The vacuum cleaner of clause 11, further comprising a pre-motorfilter assembly mounted to the hand-held portion and defining a portionof the working air path, the pre-motor filter assembly comprising atleast one pre-motor filter received within a filter chamber at an upperend of the recovery container.

14. The vacuum cleaner of clause 10 wherein the debris removal assemblycomprises a cyclonic separator chamber for separating contaminants fromthe working air path and a collection chamber for receiving contaminantsseparated in the separator chamber, the collection chamber defined atleast in part by the recovery container.

15. The vacuum cleaner of clause 14 wherein the debris removal assemblyfurther comprises a second downstream cyclonic separator chamber and asecond collection chamber for receiving contaminants separated in thesecond separator chamber.

16. The vacuum cleaner of clause 15 wherein the second downstreamcyclonic separator chamber is located concentrically within the cyclonicseparator chamber.

17. The vacuum cleaner of clause 16 wherein an inner housing isselectively receivable within the recovery container and the innerhousing defines the second downstream cyclonic separator chamber and thesecond collection chamber.

18. The vacuum cleaner of clause 17, further comprising an annular wiperconfigured to slidably contact a portion of the inner housing.

19. The vacuum cleaner of any permutation of the clauses 1-18 whereinthe base assembly further comprises an agitator chamber at the suctionnozzle and a removable brushroll selectively located therein.

20. A vacuum cleaner, comprising:

a base assembly including a suction nozzle and adapted for movementalong a surface to be cleaned;

a hand-held portion having a handle grip, a recovery container with acollector axis defined through a center thereof, and a suction source influid communication with the suction nozzle and the recovery containerand configured for generating a working airstream; and a wand operablycoupled between the base assembly and the hand-held portion and definingat least a portion of a working air path extending from the suctionnozzle to an air outlet in the hand-held portion and including thesuction source and wherein a wand axis is defined through a center ofthe wand and wherein the wand axis and the collector axis are parallel.

21. The vacuum cleaner of clause 20 wherein the suction source includesa motor/fan assembly operably coupled to the recovery container to forma single, hand-carriable unit and the motor/fan assembly defines a motoraxis that is parallel to the wand axis and the collector axis.

22. The vacuum cleaner of any permutation of the clauses 20-21 wherein agrip axis is defined through a center of the handle grip and forms anacute angle with respect to the collector axis.

23. The vacuum cleaner of clause 22, further comprising a battery packlocated on the hand-held portion and wherein a battery axis is definedthrough the center of the battery pack and intersects the grip axis atan orthogonal angle.

While aspects of the present disclosure have been specifically describedin connection with certain specific embodiments thereof, it is to beunderstood that this is by way of illustration and not of limitation.Reasonable variation and modification are possible within the scope ofthe forgoing disclosure and drawings without departing from the spiritof the present disclosure which is defined in the appended claims.Hence, specific dimensions and other physical characteristics relatingto the embodiments disclosed herein are not to be considered aslimiting, unless the claims expressly state otherwise.

1. A vacuum cleaner, comprising: a base assembly including a suctionnozzle; a hand-held portion having a hand grip, and a suction source influid communication with the suction nozzle and configured forgenerating a working airstream; a working air path from the suctionnozzle to an air outlet in the hand-held portion and including thesuction source; and a headlight array located along a forward orientedportion of the base assembly providing a beam that is substantiallyparallel to the surface to be cleaned and spaced above the surface to becleaned at not more than 30 mm.
 2. The vacuum cleaner of claim 1 whereinthe headlight array includes a plurality of LEDs spaced along a width ofthe base assembly.
 3. The vacuum cleaner of claim 2 wherein theplurality of LEDs of the headlight array have a centerline that is lessthan 20 mm above a plane defined by the surface to be cleaned.
 4. Thevacuum cleaner of claim 2 wherein the plurality of LEDs of the headlightarray provide an illuminance measurement as a delta from ambient valuesof at least 16 Lux at 2 meters and greater than 1000 Lux at 10 cm. 5.The vacuum cleaner of claim 1 wherein the beam configured to be providedby the headlight array is at a zero-degree beam angle.
 6. The vacuumcleaner of claim 1 wherein the working air path is at least partiallydefined by a wand operably coupled between the base assembly and thehand-held portion.
 7. The vacuum cleaner of claim 6 wherein the wandcomprises an outer periphery having a triangular profile.
 8. The vacuumcleaner of claim 7 wherein the wand includes a decorative insertoperably coupled to a recess within a wand body and the decorativeinsert and the wand body together form the outer periphery or whereinthe wand includes a tubular insert operably coupled within a recess of awand body and the tubular insert and the wand body together form theouter periphery.
 9. The vacuum cleaner of claim 6, further comprising aswivel joint moveably coupling a lower end of the wand to the baseassembly.
 10. The vacuum cleaner of claim 6 wherein the hand-heldportion further comprises a debris removal assembly including a recoverycontainer provided in fluid communication with the suction source. 11.The vacuum cleaner of claim 10 wherein the suction source includes amotor/fan assembly operably coupled to the debris removal assembly toform a single, hand-carriable unit.
 12. The vacuum cleaner of claim 11wherein the hand grip extends away from at least one of the motor/fanassembly or the recovery container to define a handle opening and wherethe hand grip is adapted to be gripped by a user.
 13. The vacuum cleanerof claim 11, further comprising a pre-motor filter assembly mounted tothe hand-held portion and defining a portion of the working air path,the pre-motor filter assembly comprising at least one pre-motor filter.received within a filter chamber at an upper end of the recoverycontainer.
 14. The vacuum cleaner of claim 10 wherein the debris removalassembly comprises a cyclonic separator chamber for separatingcontaminants from the working air path and a collection chamber forreceiving contaminants separated in the separator chamber, thecollection chamber defined at least in part by the recovery container.15. The vacuum cleaner of claim 14 wherein the debris removal assemblyfurther comprises a second cyclonic separator chamber that is downstreamfrom the collection chamber and a second collection chamber forreceiving contaminants separated in the second cyclonic separatorchamber.
 16. The vacuum cleaner of claim 15 wherein the second cyclonicseparator chamber is located concentrically within the cyclonicseparator chamber.
 17. The vacuum cleaner of claim 16 wherein an innerhousing is selectively receivable within the recovery container and theinner housing defines the second cyclonic separator chamber and thesecond collection chamber.
 18. The vacuum cleaner of claim 17, furthercomprising an annular wiper configured to slidably contact a portion ofthe inner housing.
 19. The vacuum cleaner of claim 1 wherein the baseassembly further comprises an agitator chamber at the suction nozzle anda removable brushroll selectively located therein.
 20. A vacuum cleaner,comprising: a base assembly including a suction nozzle; a hand-heldportion having a hand grip, a recovery container with a collector axisdefined through a center thereof, and a suction source in fluidcommunication with the suction nozzle and the recovery container andconfigured for generating a working airstream; and a wand operablycoupled between the base assembly and the hand-held portion and definingat least a portion of a working air path extending from the suctionnozzle to an air outlet in the hand-held portion and including thesuction source and wherein a wand axis is defined through a center ofthe wand and wherein the wand axis and the collector axis are parallel.21. The vacuum cleaner of claim 20 wherein the suction source includes amotor/fan assembly operably coupled to the recovery container to form asingle, hand-carriable unit and the motor/fan assembly defines a motoraxis that is parallel to the wand axis and the collector axis.
 22. Thevacuum cleaner of claim 20 wherein a grip axis is defined through acenter of the hand grip and forms an acute angle with respect to thecollector axis.
 23. The vacuum cleaner of claim 22, further comprising abattery pack located on the hand-held portion and wherein a battery axisis defined through the center of the battery pack and intersects thegrip axis at an orthogonal angle.